Decorated fireproof building substrate

ABSTRACT

A decorated fireproof building substrate includes a fireproof building substrate and a decorated multilayer. The fireproof building substrate includes a substrate and a fireproof layer, wherein the fireproof layer covers the surface of the substrate. The decorated multilayer includes an adhesive layer, a printed layer, a grain layer and a hard coating layer disposed on the fireproof building substrate subsequently. The hard coating layer is located at the outermost side of the decorated multilayer, wherein the grain layer also can has the function of the hard coating layer so as to omit the disposal of the hard coating layer.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of Taiwan applicationserial no. 103200221, filed on Jan. 6, 2014. The entirety of theabove-mentioned patent application is hereby incorporated by referenceherein and made a part of this specification.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a fireproof building substrate, and moreparticularly, to a decorated fireproof building substrate.

2. Description of Related Art

With people's increasing attention on quality of residential security, avariety of fireproof building substrates which are used as materials tobuild the building have been introduced to the market. At the same time,in order to meet the needs of aesthetics, a common approach is to adherea decoration film to the fireproof building substrate. However, for thefireproof building substrate with the adhered decoration film thereto,the decoration film may have a grain layer, a pattern layer, and amembrane thereon, which improves the flammability of the decoratedfireproof building substrate. Accordingly, it is often for the decoratedfireproof building substrate not passing a flame resistant test of thefireproof building substrate.

SUMMARY OF THE INVENTION

The invention provides a decorated fireproof building substrate, whichhas good decorative effects and fireproof effects simultaneously.

The decorated fireproof building substrate of the invention includes afireproof building substrate and a decorated multilayer. The fireproofbuilding substrate includes a substrate and a fireproof layer, whereinthe fireproof layer covers a surface of the substrate. The decoratedmultilayer includes a printed layer, a grain layer, and a hard coatinglayer disposed on the fireproof building substrate subsequently, and thehard coating layer is located at the outermost side of the decoratedmultilayer.

In an embodiment of the invention, the decorated multilayerabove-mentioned further comprises an adhesive layer, and the adhesivelayer adheres between the fireproof layer and the printed layer.

In an embodiment of the invention, the surface of the substrateabove-mentioned has a plurality of pores, and the fireproof layer atleast fills the pores.

In an embodiment of the invention, the printed layer, the grain layer,or the hard coating layer above-mentioned are further added with afireproof material.

In an embodiment of the invention, the grain layer above-mentioned has aplanar surface relatively far from the fireproof layer and a patternedsurface relatively close to the fireproof layer, and the patternedsurface has a texture structure thereon.

In an embodiment of the invention, the printed layer above-mentioned hasanother patterned surface, and the patterned surface of the printedlayer and the patterned surface of the grain layer are adhered to eachother, such that the patterned surface of the printed layer has thetexture structure thereon.

In an embodiment of the invention, an outer surface of theabove-mentioned hard coating layer has a texture structure thereon.

According to the above, the decorated fireproof building substrate ofthe invention is disposed with the decorated multilayer and thefireproof layer, so as to provide the good decorative effects and thefireproof effects.

In order to make the aforementioned and other features and advantages ofthe invention comprehensible, embodiments accompanied with figures aredescribed in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 to FIG. 3 are schematic flow diagrams of manufacturing adecorated fireproof building substrate of an embodiment of theinvention.

FIG. 4 to FIG. 5 are schematic flow diagrams of manufacturing adecorated fireproof building substrate of another embodiment of theinvention.

DESCRIPTION OF EMBODIMENTS

The invention is described in detail with reference to the accompanyingfigures. However, the invention may be embodied in various forms and isnot limited to the embodiments described herein. Orientation terms usedin the following embodiments, such as “above,”, “below, and the like,are merely referring to the orientation illustrated in the figures.Therefore, the orientation terms are used to describe the invention indetail rather than to limit the invention. In addition, the size andrelative size of each layer may be exaggerated in the figures forclarity.

FIG. 1 to FIG. 3 are schematic flow diagrams of manufacturing adecorated fireproof building substrate of an embodiment of theinvention. Please first refer to FIG. 1. First, a fireproof buildingsubstrate 100 is provided. The fireproof building substrate 100 includesa substrate 110 and a fireproof layer 120, wherein the fireproof layer120 covers a surface of the substrate 110. Material of the substrate 110includes material of first-order flame resistance, material ofsecond-order flame resistance, or material of third-order flameresistance. The substrate 110 is such as material which is used to buildthe buildings, for example, wood, marble, a cement board, a calciumsilicate board, or other material which may have a function of flameresistance after being treated.

The fireproof layer 120 covers a surface of the substrate 110. Indetail, material with the fireproof effects may be coated on the surfaceof the substrate 110 through coating methods. Then, after proceduressuch as drying, planarization, etc, the fireproof layer 120 with thefireproof effects may be formed. The fireproof layer 120 is a coatinglayer with the flame-resistant effects and the flame-retardant effects.For example, the substrate 110 is such as a material with a plurality ofpores. When the material with the fireproof effects is coated on thesurface of substrate 110, the fireproof material may penetrate into thepores of the substrate 110 to fill the pores. Preferably, besidesfilling the pores, the material with the fireproof effects may furthercover the surface of the substrate 110 completely. In addition, afterthe procedures such as drying and planarization, the fireproof layer 120may provide a planar surface, so as to facilitate a decoration film tofollow adhere to the surface of the fireproof layer 120 sequentially,and detachment due to poor adhesion is less likely to occur. In otherwords, the fireproof layer 120 not only can improve the fireproofproperties of the substrate 110, but also can enhance the adhesionstrength between the decoration film and the substrate 110.

Next, please first refer to FIG. 2. A decoration film 200 is adhered tothe fireproof building substrate 100. The decoration film 200 includesan adhesive layer 210, a printed layer 220, a grain layer 230, a hardcoating layer 240, a release layer 250, and a membrane 260 which areadhered together subsequently.

The membrane 260 is such as a flexible membrane, wherein the materialthereof may be polycarbonate (PC), acrylonitrile butadiene styrene(ABS), polyethylene terephthalate (PET), polymethylmethacrylate (PMMA),polyoxymethylene (POM), polybutylene terephthalate (PBT), polypropylene(PP), methylmethacrylate-styrene (MMA-St, MS) copolymer, polystyrene(PS), polyethylene terephthalate (PET), or the combinations thereof, butthe invention is not limited thereto.

The release layer 250 is disposed on the surface of the membrane 260,and the release layer 250 is interposed between the membrane 260 and thehard coating layer 240. The release layer 250 is mainly disposed to makethe membrane 260 temporarily adhere to the other film layers (such asthe adhesive layer 210, the printed layer 220, the grain layer 230, thehard coating layer 240, etc.), and to trip the other film layers fromthe membrane 260 after the transfer process. In addition, the releaselayer 250 is typically a film layer of low surface tension. The releaselayer 250 is composed of, for example, a matrix material (athermo-curable resin or a photo-curable resin) selectively added with atleast one of wax, paraffin, and silicone, or, the release layer 250 mayalso be composed of highly smooth and impermeable polymers.

The hard coating layer 240 may be a UV-curable resin which has highlight transmittance and anti-reflective characteristics, for example, anacrylic resin, polyurethane (PU), an epoxy resin, etc. The hard coatinglayer 240 may has a quite hardness to provide scratch-resistant andwear-resistant effects.

The grain layer 230 is disposed on the hard coating layer 240. The grainlayer 230 has a planar surface 230 a and a patterned surface 230 b. Theplanar surface 230 a is relatively far from the fireproof layer 120 andcontacts with the hard coating layer 240. The patterned surface 230 b isrelatively close to the fireproof layer 120 and contacts with theprinted layer 220. The patterned surface 230 b has a texture structurethereon. The texture structure is such as designed text or pattern whichis wish to achieve the decorative effects, wherein the texture structuremay be formed by texture stamping methods. The grain layer 230 may bethe UV-curable resin which has the high light transmittance and theanti-reflective characteristics, for example, the acrylic resin,polyurethane (PU), the epoxy resin, etc. In other embodiments, the grainlayer 230 may also be a layer of which both sides are planar surfacesand without the texture structure.

The printed layer 220 is disposed on the grain layer 230. The printedlayer 220 may also has a patterned surface 220 a, wherein the patternedsurface 220 a of the printed layer 220 and the patterned surface 230 bof the grain layer 230 are adhered to each other such that the patternedsurface 220 a has another texture structure. In detail, the printedlayer 220 is formed on the grain layer 230, so that a coating layerwhich contacts with the surface of the grain layer 230 is formed.Accordingly, on the surface of the printed layer 220 is also formed withthe texture structure which is complementary to the texture structure ofthe grain layer 230, but the invention is not limited thereto. In otherembodiments, the printed layer 220 may also be a layer of which bothsides are planar surfaces and without the texture structure. The printedlayer 220 may be composed of printing inks or printable material. Forexample, the pattern layer 220 may be an ink single layer, an inkmultilayer, or a patterned ink layer, so as to show a single-colorpattern, a multi-color pattern, or a desired pattern, respectively. Byany suitable printing process (such as gravure printing process, screenprinting process, flexographic printing process, offset printingprocess, reverse printing process, inkjet printing process, etc.), theink is able to be transferred on the grain layer 230 to form the printedlayer 220. Material of the pattern layer 220 includes polyurethane (PU)or polyacrylate, etc. which is mixed with inorganic material. Materialof the printed layer 220 includes polyurethane (PU) or polyacrylate,etc. which is mixed with inorganic material.

Preferably, during the manufacturing process of the film layers such asthe printed layer 220, the grain layer 230, or the hard coating layer240, a fireproof material may also be added to the film layers such thatthe film layers have the fireproof effects simultaneously. Material ofthe above fireproof material is such as a mixture of organic andinorganic material which has a phosphorus-containing compound, a halogencompound, an azo compound, a carbonate compound, a hydroxide, a metaloxide, or any combination thereof. In detail, the carbonate compoundincludes calcium carbonate (CaCO₃). The hydroxide includes aluminumhydroxide (Al(OH)₂), magnesium hydroxide (Mg(OH)₂). The metal oxideincludes antimony oxide, tin oxide, molybdenum oxide, or zirconiumoxide, etc. In addition, the metal oxide may be used with the halogencompound. Specifically, the halogen compound may avoid the production offree radicals during a combustion process. Calcium carbonate or the azocompound may respectively produce flame-retardant gases (such as carbondioxide or nitrogen) during combustion so as to dilute the oxygenconcentration in the air. It is easy for the hydroxide to generate watermolecules during combustion and thus having an endothermic effect.Antimony oxide together with the halogen-containing compound may diluteflammable gases and produce a flame-retardant layer during thecombustion process.

The adhesive layer 210 adheres between the fireproof layer 120 and theprinted layer 220. In other words, the decoration film 200 may adhere tothe fireproof building substrate 110 through the adhesive layer 210. Theadhesive layer 210 may be hot melt adhesive, UV-curable adhesive,photo-curable adhesive, or electron-curable adhesive. The adhesive layer210 is selected from, for example, at least one material ofpolyacrylate, polymethacrylate, polystyrene, polycarbonate,polyurethane, polyester, polyamide, epoxy resin, ethylene vinylacetatecopolymer (EVA), or thermoplastic elastomer, or copolymers, mixtures, orcomposites thereof.

The decoration film 200 is transferred to the fireproof buildingsubstrate 100 through a high-pressure transfer molding process. First, aheating and softening procedure is performed to the decoration film 200.Next, the decoration film 200 is made to contact with the fireproofbuilding substrate 100, and a pressurizing procedure is performed. Then,a high-pressure vacuum molding process is performed to the decorationfilm 200 and the fireproof building substrate 100, such that thedecoration film 200 is transferred to the fireproof building substrate100.

Next, please refer to FIG. 3. A stripping procedure is performed suchthat the release layer 250 and the membrane 260 are released from thesurface of the hard coating layer 240, and the hard coating layer 240 islocated at the outermost side of the decorated multilayer 200 a(including the printed layer 220, the grain layer 230, and the hardcoating layer 240). Thus, the manufacturing of the decorated fireproofbuilding substrate 10 a is completed.

Please refer to FIG. 3 again. The decorated fireproof building substrate10 a includes the fireproof building substrate 100 and the decoratedmultilayer 200 a. The fireproof building substrate 100 includes thesubstrate 110 and the fireproof layer 120, wherein the fireproof layer120 covers the surface of the substrate 110. The decorated multilayer200 a includes the printed layer 220, the grain layer 230, and the hardcoating layer 240 which are disposed on the fireproof building substrate100 subsequently, wherein the hard coating layer 240 is located at theoutermost side of the decorated multilayer 200 a. In addition, thedecorated multilayer 200 a further includes the adhesive layer 210,wherein the adhesive layer 210 adheres between the fireproof layer 120and the printed layer 220. The patterned surface 230 b of the grainlayer 230 faces the printed layer 220 so as to form a decorative effectof which the texture structure is toward the inside of the decoratedfireproof building substrate 10 a. Since no membrane 260 and no releaselayer 250 are disposed in the decorated fireproof building substrate 10a of the embodiment, and thus it is helpful to pass a fireproof test. Indetail, the membrane 260 and the release layer 250 are substantiallycomposed of material of lower ignition point (such as organic material).In the manufacturing process of the embodiment, the decorated multilayer200 a is kept on the fireproof building substrate 100, and the membrane260 and the release layer 250 are removed instead of being kept on thefireproof building substrate 100. Accordingly, the decorated fireproofbuilding substrate 10 a may have the beautiful decorative effect and thegood fireproof effects.

FIG. 4 to FIG. 5 are schematic flow diagrams of manufacturing adecorated fireproof building substrate of another embodiment of theinvention. The manufacturing flow in the embodiment of FIG. 4 to FIG. 5is similar to the manufacturing flow in the embodiment of FIG. 1 to FIG.3, wherein the same or similar reference numerals are used for the sameor similar components, and the same part of the description of thetechnical content is not reiterated. The differences between the twoembodiments are described in the following. First, the procedures asshown in FIG. 1 are performed, by which the fireproof building substrate100 is provided.

Next, please first refer to FIG. 4. A decoration film 200′ is adhered tothe fireproof building substrate 100. The decoration film 200′ istransferred to the fireproof building substrate 100 through, forexample, the high-pressure transfer molding process. The decoration film200′ includes the adhesive layer 210, a printed layer 220′, a hardcoating layer 240′, a release layer 250′, and the membrane 260 which aresubsequently adhered to each other. The structure of the decoration film200′ is similar to the structure of the decoration film 200 in FIG. 2,wherein the differences therebetween are that the release layer 250′ ofthe decoration film 200′ has a patterned surface 250 a, and thepatterned surface 250 a has a texture structure thereon. In addition,the hard coating layer 240′ which contacts with the patterned surface250 a of the release layer 250′ also has another patterned surface 240a, wherein the patterned surface 240 a also has the texture structurethereon. In detail, in the embodiment, the release layer 250′ with thetexture structure is formed on the membrane 260, and then the hardcoating layer 240′ is formed on the release layer 250′. Accordingly, thepatterned surface 240 a of the hard coating layer 240′ and the patternedsurface 250 a of the release layer 250′ are adhered to each other, andthus the patterned surface 240 a has another texture structure.

Next, please refer to FIG. 5. The stripping procedure is performed suchthat the release layer 250′ and the membrane 260 are released from thesurface of the hard coating layer 240′, and the patterned surface 240 aof the hard coating layer 240′ is located at the outermost side of thedecorated multilayer 200 b (including the printed layer 220′ and thehard coating layer 240′). Thus, the manufacturing of the decoratedfireproof building substrate 10 b is completed.

Please refer to FIG. 5 again. The decorated fireproof building substrate10 b includes the fireproof building substrate 100 and the decoratedmultilayer 200 b. The fireproof building substrate 100 includes thesubstrate 110 and the fireproof layer 120, wherein the fireproof layer120 covers the surface of the substrate 110. The decorated multilayer200 b includes the printed layer 220′ and the hard coating layer 240′which are disposed on the fireproof building substrate 100 subsequently,wherein the patterned surface 240 a of the hard coating layer 240′ islocated at the outermost side of the decorated multilayer 200 b so as toform a decorative effect of which the texture structure is toward theoutside of the decorated fireproof building substrate 10 b. Furthermore,the decorated multilayer 200 b further includes the adhesive layer 210,wherein the adhesive layer 210 adheres between the fireproof layer 120and the printed layer 220′. Since no membrane 260 and no release layer250′ are disposed in the decorated fireproof building substrate 10 b ofthe embodiment, and thus it is helpful to pass the fireproof test. Indetail, the membrane 260 and the release layer 250′ are substantiallycomposed of the material of lower ignition point (such as organicmaterial). In the manufacturing process of the embodiment, the decoratedmultilayer 200 b is kept on the fireproof building substrate 100, andthe membrane 260 and the release layer 250′ are removed instead of beingkept on the fireproof building substrate 100. Accordingly, the decoratedfireproof building substrate 10 b may have the beautiful decorativeeffect and the good fireproof effects.

The Fireproof Test of the Decorated Fireproof Building Substrate

The substrate of the decorated fireproof building substrate of theinvention is such as the calcium silicate board. Material of thefireproof layer is such as the resin containing inorganic material, forexample, a coating material added with substances having theflame-resistant effect. The decorated multilayer is adhered to thefireproof layer, and the structure thereof id shown in FIG. 3. A CNSflame resistant test is performed on the above-mentioned decoratedfireproof building substrate, wherein the heating temperature is 720° C.to 730° C., and the heating time is 20 minutes.

According to the above, the decorated fireproof building substrate ofthe invention is disposed with the decorated multilayer so as to providethe good decorative effects. The decorated fireproof building substrateabove is disposed with the fireproof layer so as to provide thefireproof effects. Moreover, no release layer and no membrane aredisposed on the decorated multilayer and thus it is difficult to burndue to high temperature. Accordingly, the fireproof effects of thedecorated fireproof building substrate may be effectively enhanced.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the structure of thedisclosed embodiments without departing from the scope or spirit of theinvention. In view of the foregoing, it is intended that the disclosurecover modifications and variations of this specification provided theyfall within the scope of the following claims and their equivalents.

What is claimed is:
 1. A decorated fireproof building substrate,comprising: a fireproof building substrate, comprising a substrate and afireproof layer, wherein the fireproof layer covers a surface of thesubstrate; and a decorated multilayer, comprising a printed layer, agrain layer, and a hard coating layer disposed on the fireproof buildingsubstrate subsequently, wherein the hard coating layer is located at theoutermost side of the decorated multilayer.
 2. The decorated fireproofbuilding substrate as claimed in claim 1, wherein the decoratedmultilayer further comprises an adhesive layer, and the adhesive layeradheres between the fireproof layer and the printed layer.
 3. Thedecorated fireproof building substrate as claimed in claim 1, whereinthe surface of the substrate has a plurality of pores, and the fireprooflayer at least fills the pores.
 4. The decorated fireproof buildingsubstrate as claimed in claim 1, wherein the printed layer, the grainlayer, or the hard coating layer are further added with a fireproofmaterial.
 5. The decorated fireproof building substrate as claimed inclaim 1, wherein the grain layer has a planar surface relatively farfrom the fireproof layer and a patterned surface relatively close to thefireproof layer, and the patterned surface has a texture structurethereon.
 6. The decorated fireproof building substrate as claimed inclaim 5, wherein the printed layer has another patterned surface, andthe patterned surface of the printed layer and the patterned surface ofthe grain layer are adhered to each other, such that the patternedsurface of the printed layer has the texture structure thereon.
 7. Thedecorated fireproof building substrate as claimed in claim 1, wherein anouter surface of the hard coating layer has a texture structure thereon.